Automated heat exchanger tube cleaning assembly and system

RELATED APPLICATIONS

0001This divisional application claims the benefit, and priority benefit, of U.S. application Ser. No. 12/383,183, filed Mar. 20, 2009 now U.S. Pat. No. 8,057,607, titled “Automated Heat Exchanger Tube Cleaning Assembly and System,” which claims the benefit, and priority benefit, of U.S. Provisional Patent Application Ser. No. 61/070,073, filed Mar. 20, 2008, also titled “Automated Heat Exchanger Tube Cleaning Assembly and System,” the contents of all of which are incorporated herein in their entirety.

BACKGROUND

00021. Field of Invention

0003This invention relates generally to the cleaning of heat exchangers, and more particularly, to an apparatus and system for removing residue which accumulates over time in heat exchangers and other tubing and piping used in industrial facilities.

00042. Description of the Related Art

0005Heat exchangers are commonly used in industrial facilities. Over time, these heat exchangers tend to develop residue on the surfaces of the tubes, tube sheets, tube support plates and other internal structural parts. The residue can comprise adherent films, scales, sludge deposits, corrosion and/or other similar materials. Over time, this residue can have an adverse affect on the operational performance of the exchangers. The same problem can arise for all piping and tubing found in industrial facilities.

0006Various cleaning devices and methods have been developed to remove this residue buildup from heat exchangers, tubes and other piping. A common method involves the controlled application of high pressure water and/or chemical streams to the affected areas of the heat exchanger. This method can require the presence of one or more persons at or near the point of application of the high pressure stream to the exchanger during the cleaning process.

0007For example, an operator may stand in clear view of, and near the line-of-fire of, the high pressure stream to direct the stream to the affected areas of the exchanger. Another person may be needed to operate a control panel next to the exchanger to further control the direction and volume of stream flow. This type of work is extremely labor intensive and potentially hazardous. For example, it may be necessary for crews to manually reposition the device providing the high pressure stream for each cleaning stroke. Further, those persons in close proximity to the cleaning environment can be exposed to high pressure water, hazardous cleaning chemicals or other potentially toxic, poisonous or volatile materials.

SUMMARY OF THE INVENTION

0008In accordance with the illustrative embodiments hereinafter described, an automated heat exchanger tube cleaning assembly and system are provided. In an embodiment, the system can automatically (without ongoing human intervention) survey the tube sheet of a heat exchanger in three dimensions, convert and record the survey results as a digital file in three dimensions, and then, according to sequential parameters input via custom software, automatically coordinate via computer one or more cleaning devices such as lances to effect the cleaning of each desired tube of the heat exchanger.

0009In an illustrative embodiment, a system for cleaning tubes in a heat exchanger may include a scanning device for capturing three dimensional coordinates corresponding to the location of the tubes in the heat exchanger to be cleaned, a heat exchanger tube cleaning lance, a heat exchanger tube cleaning lance positioning device, and a motion control computer for controlling the motion of the heat exchanger tube cleaning lance positioning device with respect to the tubes in the heat exchanger based upon the three dimensional coordinates captured by the laser surface scanning device. In an illustrative embodiment, the scanning device can be a sensor. Further, the sensor can be, for example, a laser.

0010A command console may be in operational connection with the motion control computer for controlling the motion of the heat exchanger tube cleaning lance positioning device from a remote location. The system may function as a completely automated system or a remote controlled system, as desired. A pumping station may supply cleaning materials (including, but not limited to, high-pressure water to approximately 50,000 PSI) to the heat exchanger tube cleaning lance. The respective structures and movements of the heat exchanger tube cleaning lance and the laser surface scanning device may be independent of each other.

0011In another illustrative embodiment, a method of cleaning one or more tubes in a heat exchanger is provided. The method can include, for example, the steps of digitally surveying the heat exchanger tube sheet in three dimensions to determine the location of the heat exchanger tubes, positioning a tube cleaning device adjacent to the heat exchanger tube sheet, and aligning the tube cleaning device with the heat exchanger tubes based upon the tube locations determined by the digital survey. The survey results obtained from the digital survey may be stored in a motion control computer. Each of the steps of digitally surveying, positioning, and aligning may be controlled by a motion control computer. Further, the location of the motion control computer may be remote from the location of the tube cleaning device.

0012In another illustrative embodiment, a recalibration system and related method are provided that allow for automatically recalibrating the position of a cleaning lance with respect to one or more heat exchanger targets. The computer motion controller may, in accordance with user-defined time intervals or as a result of a missed target, move the tip of the cleaning lance to a three dimensional coordinate value known by the computer to be the position of a recalibration sensor. The recalibration sensor may be temporarily rigidly fixed to the heat exchanger shell during identification of the initial three dimensional coordinate point having a specific coordinate value. This three dimensional coordinate value can be measured and delivered to the computer prior to starting the cleaning. When the lance tip is at the coordinate point, and assuming no shifting of the lance tip relative to the exchanger has occurred, the computer may receive an input signal from a sensor or set of sensors that have detected the lance tip and confirmed that it is in the proper location, such as, for example, through the use of thru-beam optical sensors, non-contact proximity sensors, contact proximity sensors, or digital imaging sensors. If the lance has shifted, then a different input signal can be received, and repositioning information may be obtained by the nature of the signal such that the computer may make the slight adjustment of the lance's position relative to the recalibration sensor, and then move to the 3-D point again to confirm recalibration has been successful. The computer controller may then move back to the next cleaning target and resume the cleaning operation.

0013In another illustrative embodiment, a system for cleaning one or more tubes on the tube sheet of a heat exchanger is provided. The system can include a display for presenting a map of at least a portion of the tube sheet, a user input device for defining a cleaning region on the map and for identifying at least one tube within the cleaning region, a tube cleaning lance for accessing one or more tubes on the tube sheet, a tube cleaning lance positioning device for maneuvering the tube cleaning lance, and a motion control computer for navigating the motion of one or more of the tube cleaning lance and the tube cleaning lance positioning device with respect to the tubes on the tube sheet by utilizing information received from the user input device.

0014The user input device can be one or more of a touch screen, a joystick controller, a mouse and a trackball. The tube cleaning lance can access the one or more tubes on the tube sheet in any order desired, for example, simultaneously or sequentially. The motion control computer can be communicatively coupled to a remote monitoring device via a communications network. The location of the motion control computer can be a remote distance from the location of the tube cleaning lance positioning device. A pumping station can be operationally controlled by the motion control computer for supplying cleaning materials to the tube cleaning lance.

0015In another illustrative embodiment, a method of maneuvering a heat exchanger tube cleaning device with respect to a tube sheet of a heat exchanger is provided. A map of at least a portion of the tube sheet can be provided. User input can be accepted regarding a plurality of reference points within the map, the plurality of reference points defining the location of a plurality of tubes to be cleaned on the tube sheet. The motion of the tube cleaning device can be navigated with respect to the plurality of reference points. The navigation may be manual or automatically controlled.

0016In another illustrative embodiment, a method of maneuvering a heat exchanger tube cleaning device with respect to a tube sheet of a heat exchanger is provided. A map of at least a portion of the tube sheet can be provided. User input can be accepted regarding a plurality of reference points within the map, the plurality of reference points defining the perimeter of a cleaning region with one or more tubes to be cleaned located therein. The motion of the tube cleaning device can be navigated with respect to the plurality of reference points and the one or more tubes located within the cleaning region. The navigation may be manual or automatically controlled.

0017In another illustrative embodiment, a method of cleaning one or more tubes on the tube sheet of a heat exchanger is provided. A tube cleaning device can be positioned adjacent to the tube sheet. A map can be provided of at least a portion of the tube sheet. User input can be accepted on a motion control computer regarding a plurality of reference points on the map, the plurality of reference points corresponding to a plurality of tubes on the tube sheet that define the perimeter of a cleaning region. The motion of the tube cleaning device can be navigated to the plurality of tubes on the tube sheet that define the perimeter of the cleaning region. The navigation may be manual or automatically controlled. The tube cleaning device can be instructed to clean the plurality of tubes on the tube sheet that define the perimeter of the cleaning region. The location of one or more tubes located within the cleaning region may be identified. The motion of the tube cleaning device can be navigated to the one or more tubes located within the cleaning region using the motion control computer. The tube cleaning device can be instructed to clean the one or more tubes located within the cleaning region. The motion of the tube cleaning device can be automatically navigated to the plurality of tubes on the tube sheet that define the perimeter of the cleaning region or to the one or more tubes located within the cleaning region using the motion control computer.

0018In another illustrative embodiment, a method of cleaning one or more tubes on the tube sheet of a heat exchanger is provided. A tube cleaning device can be positioned adjacent to the tube sheet. A map may be provided of at least a portion of the tube sheet. User input can be accepted on a motion control computer regarding a plurality of reference points on the map, the plurality of reference points corresponding to a plurality of tubes that define the perimeter of a cleaning region. The location of one or more tubes located within the cleaning region can be identified. The motion of the tube cleaning device can be navigated to the plurality of tubes that define the perimeter of a cleaning region and the one or more tubes located within the cleaning region using the motion control computer. The navigation may be manual or automatically controlled. The tube cleaning device can then be instructed to clean the tubes.

BRIEF DESCRIPTION OF THE DRAWINGS

0019<figref idref="DRAWINGS">FIG. 1</figref> is a schematic view of a heat exchanger tube cleaning assembly in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0020<figref idref="DRAWINGS">FIG. 2</figref> is a perspective, schematic view of a control console for use in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0021<figref idref="DRAWINGS">FIG. 3</figref> is a schematic view of a command trailer for use in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0022<figref idref="DRAWINGS">FIG. 4</figref> is a cross sectional view of a heat exchanger showing the tubes running through the exchanger and terminating at each end in a tube sheet.

0023<figref idref="DRAWINGS">FIG. 5</figref> is an end plan view of a tube sheet showing the exchanger head flange and an open end of each of the tubes in the exchanger of <figref idref="DRAWINGS">FIG. 4</figref>.

0024<figref idref="DRAWINGS">FIGS. 6-10</figref> are perspective views of a cleaning lance and related components in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0025<figref idref="DRAWINGS">FIGS. 11 &amp; 12</figref> are perspective views of a cleaning lance positioning device in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0026<figref idref="DRAWINGS">FIGS. 13 &amp; 14</figref> are perspective views of a frame for the cleaning lance positioning device of <figref idref="DRAWINGS">FIGS. 11 &amp; 12</figref>.

0027<figref idref="DRAWINGS">FIG. 15</figref> is an end plan view of a scanning device in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0028<figref idref="DRAWINGS">FIGS. 16A</figref>, B &amp; C are side and end plan views of a centering jig for a cleaning lance in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0029<figref idref="DRAWINGS">FIG. 17</figref> is a side view of a recalibration system in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0030<figref idref="DRAWINGS">FIG. 18</figref> is a side view of a positive polarity probe in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0031<figref idref="DRAWINGS">FIG. 19</figref> is a perspective view of a plurality of cleaning lances and a bracelet in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0032<figref idref="DRAWINGS">FIGS. 20A</figref> &amp; B are a front view of a command station in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0033<figref idref="DRAWINGS">FIG. 21</figref> is a front view of an exchanger information screen on a command station in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0034<figref idref="DRAWINGS">FIG. 22</figref> is a front view of a cleaning information screen on a command station in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0035<figref idref="DRAWINGS">FIG. 23</figref> is a front view of an section definition screen on a command station in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0036<figref idref="DRAWINGS">FIG. 24A</figref> &amp; B are front views of an edit screen for a manual process in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0037<figref idref="DRAWINGS">FIGS. 25A</figref>, B, C &amp; D are front views of an edit screen for an iterative process in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0038<figref idref="DRAWINGS">FIG. 26</figref> is a front view of an edit screen for an iterative process with cleaning in progress in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0039<figref idref="DRAWINGS">FIG. 27</figref> is a perspective view of a lance track adjustment ram in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0040<figref idref="DRAWINGS">FIGS. 28-33</figref> are flow diagrams for various embodiments of an automated heat exchanger tube and industrial tube/pipe cleaning process and system.

0041<figref idref="DRAWINGS">FIGS. 34-36</figref> are perspective views of a tube cleaning lance rotating device in an embodiment of an automated heat exchanger tube and industrial tube/pipe cleaning assembly and system.

0042While certain preferred illustrative embodiments will be described herein, it will be understood that this description is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

0043Referring now to <figref idref="DRAWINGS">FIG. 1</figref>, an illustrative embodiment of an automated heat exchanger tube cleaning assembly <b>10</b> and related system is provided. Assembly <b>10</b> allows for automated tube lancing of a heat exchanger <b>12</b> or other piping or equipment used in an industrial facility such as, for example, a petrochemical plant or oil refinery. Assembly <b>10</b> is positioned adjacent exchanger <b>12</b> to be cleaned. Assembly <b>10</b> can facilitate the delivery of one or more streams of cleaning materials such as high-pressure water and/or chemicals to the inside of tubes <b>88</b> (see <figref idref="DRAWINGS">FIG. 4</figref>) inside exchanger <b>12</b>. The pressurized cleaning stream removes residue build-up from the inside of these tubes <b>88</b> as well as other affected areas.

0044Operations of assembly <b>10</b> can be controlled by a control console <b>20</b>, as illustrated in <figref idref="DRAWINGS">FIG. 2</figref>. In an illustrative embodiment, control console <b>20</b> is remotely located from assembly <b>10</b>. For example, referring back to <figref idref="DRAWINGS">FIG. 1</figref>, control console <b>20</b> can communicate with assembly <b>10</b> via hardwiring, such as an umbilical cable <b>22</b>. Cable <b>22</b> can connect control console <b>20</b> to assembly <b>10</b> via, for example, an assembly control module <b>24</b> adjacent to assembly <b>10</b>. Alternatively, assembly <b>10</b> can communicate with control console <b>20</b> via a wireless communications network, which can take the form of radio signals, Internet or other similar communication forms. Control console <b>20</b> can allow for precision control by an operator of assembly <b>10</b> at a location that is remote, that is, physically distant, from the location of exchanger <b>12</b>.

0045In a specific illustrative embodiment, control console <b>20</b> is located in a command trailer <b>40</b> (<figref idref="DRAWINGS">FIGS. 1 &amp; 3</figref>). Alternatively, control console <b>20</b> may also be utilized in the absence of trailer <b>40</b>. Command trailer <b>40</b> is preferably a safe, controlled environment and can include central heat and A/C. Command trailer <b>40</b> can also include its own power source <b>42</b> such as, for example, a built-in 7 KW generator with multiple GFCI outlets and 12-Volt regulated power supply in an illustrative embodiment. Trailer <b>40</b> can also be mobile so that it can be moved from location to location as desired.

0046Control console <b>20</b> can be integrated with a command station <b>44</b> within trailer <b>40</b>. Command station <b>44</b> can include, in addition to control console <b>20</b>, video monitor screens <b>46</b> and appropriate dials, switches and other instruments for controlling the operation of assembly <b>10</b> and its related features and components.

0047One or more video cameras <b>30</b> (<figref idref="DRAWINGS">FIG. 1</figref>) can be utilized so that, for example, video signals may be delivered to command station <b>44</b> and viewed on video monitor screens <b>46</b>. Cameras <b>30</b> can provide clear, high-definition video capture and live feed to command station <b>44</b>. Antennas <b>50</b> (<figref idref="DRAWINGS">FIG. 1</figref>) may be utilized to facilitate the delivery of communications between, for example, trailer <b>40</b> and the cameras <b>30</b> of assembly <b>10</b>.

0048In an illustrative embodiment, a series of four cameras <b>30</b><i>a</i>, <b>30</b><i>b</i>, <b>30</b><i>c</i>, &amp; <b>30</b><i>d </i>can feed images to command station <b>44</b>. The cameras <b>30</b><i>a</i>, <b>30</b><i>b</i>, <b>30</b><i>c</i>, &amp; <b>30</b><i>d </i>preferably have full remote-control pan, tilt, and zoom as well as near-infrared capability and completely waterproof enclosures. Two cameras <b>30</b><i>a</i>, <b>30</b><i>b </i>can display the work at the exchanger tube sheet in close-up detail to, for example, allow a process operator to safely watch the work as it occurs and/or to guide him in real time if he elects to control the cleaning process from a remote location. Third camera <b>30</b><i>c </i>can display the entire exchanger <b>12</b> and assembly <b>10</b>. Fourth camera <b>30</b><i>d </i>can be positioned atop command trailer <b>40</b> to display the area around a pump <b>60</b> and trailer <b>62</b>. Pump <b>60</b> disposed on trailer <b>62</b> supplies pressurized cleaning materials to assembly <b>10</b> via tubing <b>64</b>. Cameras <b>30</b><i>a</i>, <b>30</b><i>b</i>, <b>30</b><i>c </i>and <b>30</b><i>d </i>can be moved or repositioned as necessary to obtain the desired view of the system.

0049In an illustrative embodiment, a pan and tilt joystick controller <b>70</b> (<figref idref="DRAWINGS">FIG. 2</figref>) can be used to control the various directional movements of components of assembly <b>10</b>, for example, one or more cleaning lances <b>90</b> (<figref idref="DRAWINGS">FIG. 1</figref>) for cleaning the tubes of exchanger <b>12</b>. Joystick controller <b>70</b> can comprise, for example, any recognized user input device such as a touch screen, a joystick controller, a mouse or a trackball, and would be in accordance with the present illustrative embodiments. Controller <b>70</b> can be located on control console <b>20</b> if desired. Controller <b>70</b> or a similar controller can also be used to move video cameras <b>30</b><i>a</i>, <b>30</b><i>b</i>, <b>30</b><i>c</i>, &amp; <b>30</b><i>d </i>about their vertical and longitudinal axes, thereby enlarging the field of view. Cameras <b>30</b><i>a</i>, <b>30</b><i>b</i>, <b>30</b><i>c</i>, &amp; <b>30</b><i>d </i>can also utilize zoom lens controllers in order to adjust the magnification factor such that assembly <b>10</b> and exchanger <b>12</b> may be monitored at whatever magnification is desired. Lens washer systems for the lenses of cameras <b>30</b><i>a</i>, <b>30</b><i>b</i>, <b>30</b><i>c</i>, and <b>30</b><i>d </i>may also be provided, which can direct a cleaning media across these lenses to wash away any accumulation of debris from the camera lenses.

0050<figref idref="DRAWINGS">FIGS. 4 and 5</figref> show an illustrative embodiment of heat exchanger <b>12</b>. Exchanger <b>12</b> can have one or more tube sheets <b>80</b> accessible by removing an exchanger head <b>82</b> connected to a heat exchanger head flange <b>84</b>. Each tube sheet <b>80</b> can have an open end <b>86</b> which exposes a plurality of tubes <b>88</b> having flow passageways in exchanger <b>12</b>. Residue can accumulate in or near, among other areas, the flow passageways of tubes <b>88</b>.

0051<figref idref="DRAWINGS">FIGS. 6-10</figref> show illustrative embodiments of cleaning lance <b>90</b> and related components associated with assembly <b>10</b>. It is recognized, however, that other cleaning instruments can also be utilized and would be in accordance with the present illustrative embodiments. Lance <b>90</b> can emit high pressure cleaning materials and can be rigid, semi-rigid or flexible as desired. Lance <b>90</b> can include a plurality of nozzles <b>96</b> on its outer surface through which cleaning materials are emitted. Further, lance <b>90</b> can rotate within tube <b>88</b> to allow for better distribution of cleaning materials. A tip end <b>92</b> of cleaning lance <b>90</b> (as shown in <figref idref="DRAWINGS">FIGS. 6-10</figref>) may be inserted into and through each of tubes <b>88</b> of exchanger <b>12</b> by passing tip end <b>92</b> of cleaning lance <b>90</b> through open ends <b>86</b> of tubes <b>88</b> provided on tube sheet <b>80</b>. Nozzles <b>96</b> can be located on tip end <b>92</b> in an illustrative embodiment.

0052A guide tube <b>94</b> (<figref idref="DRAWINGS">FIGS. 6-8</figref>) can guide and control cleaning lance <b>90</b> as it extends into and through each of tubes <b>88</b>. In an illustrative embodiment, guide tube <b>94</b> can be shaped like a gun barrel. There is preferably a tight tolerance between cleaning lance <b>90</b> and the inside walls of guide tube <b>94</b> to restrict unnecessary movement and promote efficient cleaning.

0053Control panel <b>20</b> can be used to regulate the movement of cleaning lance <b>90</b>. For example, control panel <b>20</b> can control the distance that cleaning lance <b>90</b> extends out of, or retracts into, guide tube <b>94</b>, or the rotational speed of lance <b>90</b> within tube <b>88</b>. Also, control panel <b>20</b> can independently control the movement of one or more of guide tube <b>94</b>, cleaning lance <b>90</b> and/or assembly <b>10</b>. Also, control panel <b>20</b> can include indicators for lance revolutions per minute (RPM) and feet per second (FPS), as well as closed-loop feedback control circuit for positioning assembly <b>10</b>. These types of indicators can allow for semi-automated control of motion parameters for lance <b>90</b> via, for example, programmable set-points for minimum and maximum allowable lance speed (linear and angular) and position.

0054Control panel <b>20</b> can also be used to regulate the operations of pump <b>60</b>, or any other pumps utilized in connection with assembly <b>10</b>. For example, an operator may start and stop pump <b>60</b> and have access to information regarding pump operations via control panel <b>20</b>.

0055In an illustrative embodiment, cleaning lance <b>90</b> and guide tube <b>94</b> can be housed within a heat exchanger tube cleaning lance positioning device <b>91</b> (FIGS. <b>1</b> &amp; <b>11</b>-<b>12</b>) that can be part of assembly <b>10</b>. Joystick controller <b>70</b> can also preferably control the movements of device <b>91</b>. One or more of cleaning lance <b>90</b> and guide tube <b>94</b> can be manipulated and positioned for cleaning each tube <b>88</b> of exchanger <b>12</b> by using heat exchanger tube cleaning lance positioning device <b>99</b>. Device <b>91</b> can be any device that is integrated with assembly <b>10</b> and can be used to control and maneuver the movements of one or more of lance <b>90</b> and guide tube <b>94</b> and fall within the present illustrative embodiments. Assembly <b>10</b> can be disposed within a frame <b>95</b>, if desired (<figref idref="DRAWINGS">FIGS. 13-14</figref>). Frame <b>95</b> is preferably utilized to connect assembly <b>10</b> to exchanger <b>12</b>, such that cleaning lance positioning device <b>91</b> will have little or no movement relative to exchanger <b>12</b> and guide tube <b>94</b> is rigid with respect to exchanger <b>12</b>. In an illustrative embodiment, heat exchanger tube cleaning lance positioning device <b>91</b> is positioned on a solid stand and can have an adaptable universal bracket kit (not shown) that allows it to be fixed to nearly any type of exchanger, even vertical reboilers, with no scaffolding required. Heat exchanger tube cleaning lance positioning device <b>91</b> can also be positioned on wheels, if desired, so long as the wheels do not substantially affect movement of device <b>91</b> with respect to exchanger <b>12</b> during cleaning.

0056As illustrated in <figref idref="DRAWINGS">FIG. 15</figref>, an independent laser (or other sensor) surface scanning device <b>100</b> can be utilized to determine three dimensional (“3-D”) coordinate targets and create a full resolution digital map of head flange <b>84</b>, tube sheet <b>80</b>, tubes <b>88</b> and tube open ends <b>86</b> of heat exchanger <b>12</b>. In an illustrative embodiment, a scanning device <b>100</b> similar in construction to the MicroScribe digitizer and RSI 3D laser system provided by Immersion Corporation of San Jose, Calif. can be utilized. Scanning device <b>100</b> can move in three dimensions while controlled solely via motion control computer <b>120</b>. For example, device <b>100</b> can measure the distance between the end of guide tube <b>94</b> and tube sheet <b>80</b> of exchanger <b>12</b> as a z-axis measurement. Three-dimensional coordinate mapping can allow for inclusion of precise digital data from the x, y and z coordinates, which eliminates errors which can result from roll, pitch, skew or yaw measured in two-dimensional environments only.

0057In an illustrative embodiment, scanning device <b>100</b> can be mounted upon tube sheet <b>80</b> of exchanger <b>12</b> using scanning mount <b>102</b> (<figref idref="DRAWINGS">FIG. 15</figref>). Scanning mount is preferably not attached to assembly <b>10</b>, positioning device <b>91</b> and/or cleaning lance <b>90</b>, so that the respective movements of scanning device <b>100</b> and cleaning lance <b>90</b> are independent of each other. Thus, scanning device <b>100</b> can be removed from exchanger <b>12</b> after scanning has occurred but prior to cleaning of the exchanger, to prevent flying debris from damaging scanning device <b>100</b>.

0058Tube sheets <b>80</b> can be optically scanned by scanning device <b>100</b>, and the scanned images can be delivered to motion control computer <b>120</b> (<figref idref="DRAWINGS">FIG. 1</figref>) affiliated with control console <b>20</b> and command station <b>44</b> prior to beginning cleaning. The position of scanning device <b>100</b> and the position of tubes <b>88</b> can be synchronized for computer numerically controlled (CNC) operation. Then the operator can switch between joystick controller <b>70</b> or complete automation as desired.

0059In an illustrative embodiment (see <figref idref="DRAWINGS">FIG. 15</figref>), scanning device <b>100</b> may scan one or more images of tube sheet <b>80</b> and open ends <b>86</b> of tubes <b>88</b> to be cleaned. The scanned images can be sent to control console <b>20</b> and stored in motion control computer <b>120</b>. Motion control computer <b>120</b> can inspect and analyze the scanned images and identify each open end <b>86</b> and each associated flow passageway of each tube <b>88</b> in exchanger <b>12</b>. Motion control computer <b>120</b> may then calculate the precise relative x-y-z coordinates of the center of each tube <b>88</b> at its plane of intersection with tube sheet <b>80</b>. These initial coordinates can be stored to file for the particular exchanger <b>12</b>. In an illustrative embodiment, no future scans are required.

0060After the initial scan has occurred, a centering jig <b>140</b> (as shown in <figref idref="DRAWINGS">FIGS. 16</figref><i>a, b </i>&amp; <i>c</i>) can be utilized to position guide tube <b>94</b> adjacent to exchanger <b>12</b> and stabilize guide tube <b>94</b> relative to tube sheet <b>80</b>. In a preferred illustrative embodiment, centering jig <b>140</b> can comprise a cone-tip <b>140</b>-A and a tube insert <b>140</b>-B. Cone tip <b>140</b>-A and tube insert <b>140</b>-B can each be formed of polyethylene plastic in a specific embodiment. A back end <b>141</b> of tube insert <b>140</b>-B can snap into the barrel of tube <b>88</b>, while a front end <b>142</b> of tube insert <b>140</b>-B may be exposed and can have a female cone <b>143</b> formed therein. Female cone <b>143</b> can receive a male point <b>144</b> of cone-tip <b>140</b>-A. When male point <b>144</b> is disposed within female cone <b>143</b>, guide tube <b>94</b> is sufficiently adjacent to exchanger <b>12</b> and stabilized relative to tube sheet <b>80</b>. The size of tube insert <b>140</b>-B can depend upon the diameter of tube <b>88</b> within which insert <b>140</b>-B is positioned.

0061Joystick controller <b>70</b> can be utilized to position tip end <b>92</b> of cleaning lance <b>90</b> at the center of a minimum of three unique targets at the surface of tube sheet <b>80</b>. Motion control computer <b>120</b> can determine the orientation of jig <b>140</b> relative to the previously stored x-y-z coordinates and calculate the most desirable location for cleaning lance <b>90</b>.

0062Scanning device <b>100</b> (See <figref idref="DRAWINGS">FIG. 15</figref>) can be recalibrated or realigned on a continuous basis, to adjust for any changes relative to the initial coordinates calculated at the beginning of the cleaning process. These possible changes can be a result of, for example, shifting of assembly <b>10</b> or its components relative to exchanger <b>12</b>. Either non-contact or contact type position indicating feedback sensors can be utilized during recalibration to guide the computer motion controller.

0063In an illustrative embodiment, a recalibration disc <b>150</b> as shown in <figref idref="DRAWINGS">FIG. 17</figref> can be utilized to recalibrate the system. Disc <b>150</b> can be attached to head flange <b>84</b> of exchanger <b>12</b>. Recalibration disc <b>150</b> can comprise a solid disc of thermosetting polymer encasing a plurality of parallel, insulated, color-coded copper wires. The direction of the wires can be perpendicular to the plane formed by the flat surface of recalibration disc <b>150</b>.

0064The front face of recalibration disc <b>150</b> can be sanded flat until the conductor of each wire in recalibration disc <b>150</b> is exposed as a conductive point on the flat plane. The wires can extend out of recalibration disc <b>150</b> on the backside and be chemically soldered into one half of a multi-conductor electronics plug. Recalibration disc <b>150</b> can then be silicone-bedded into a corresponding stainless steel cup, with the contact plane facing the open side and the connector plug protruding from the back. A removable snap-on face plate <b>152</b> can cover the contact side of recalibration disc <b>150</b>.

0065In an illustrative embodiment, face plate <b>152</b> can have a plurality of small, spring loaded stainless steel pins <b>154</b> installed individually from the inside thereof When face plate <b>152</b> is in place, an individual pin <b>154</b> can be positioned over each contact wire, and in the normal position the spring tension preferably does not allow pin <b>154</b> and the contact wire to touch. If a positive external force is applied to the outer surface of plate <b>152</b> and parallel to the wires in the bundle, the particular stainless pins <b>154</b> under the load can slide down and make contact with the wires under them.

0066As illustrated in <figref idref="DRAWINGS">FIG. 17</figref>, recalibration disc <b>150</b> can be bolted via a bracket <b>156</b> to exchanger <b>12</b> in a position which allows recalibration disc <b>150</b> to reach exchanger <b>12</b> through x-y-z movement. The multi-pin plug can be connected to the input/output field bus at the control console <b>20</b>, and signals (such as low-voltage on/off, or yes/no circuit completion inputs) from recalibration disc <b>150</b> can be interpreted by the motion control computer <b>120</b> and compared to expected values to determine position and to adjust motion output accordingly.

0067As illustrated in <figref idref="DRAWINGS">FIG. 18</figref>, a positive polarity probe <b>200</b> can be rigidly fixed to the end of guide tube <b>94</b>. Probe <b>200</b> can guide and control cleaning lance <b>90</b> as it is being positioned from target to target on exchanger <b>12</b>. Probe <b>200</b> may be constantly energized via, for example, a lithium ion battery pack. In an illustrative embodiment, cleaning lance <b>90</b> can be formed of rigid stainless steel tubing and can move in and out through guide tube <b>94</b> with a critical tolerance that prevents backlash between lance <b>90</b> and guide tube <b>94</b>, either repetitive and predictable or intermittent and unpredictable, that could compromise accuracy and/or precision of movement.

0068Upon initial set-up and after scanning device <b>100</b> has gathered its three dimensional coordinates and determined its current positioning relative to those coordinates, assembly <b>10</b> can be instructed by motion control computer <b>120</b> to begin an initial calibration procedure. Cleaning lance <b>90</b> can then be manually guided via control console <b>20</b> until positive polarity probe <b>200</b> on guide tube <b>94</b> makes contact with the center conductor pin <b>154</b> of recalibration disc <b>150</b>. This contact can trigger motion control computer <b>120</b> to recall the x-y-z coordinates for this point, and recognize that these coordinates should always result in an input signal from the center wire. Scanning device <b>100</b> can periodically re-check the coordinates to confirm the signal.

0069If positive polarity probe <b>200</b> on guide tube <b>94</b> does not make contact with the center conductor pin <b>154</b> of recalibration disc <b>150</b>, it can contact one or more of several hundred other pins resulting in a different input. At this point, motion control computer <b>120</b> can recognize exactly where positive polarity probe <b>200</b> is located relative to center conductor pin <b>154</b> due to the known geometry of the conductor spacing, and can deliver an appropriate output to the x-y-z motion system (the servomotors that control all motion) to attempt to hit center conductor pin <b>154</b> only. Motion control computer <b>120</b> can continue this trial-and-error loop until it once again finds center conductor pin <b>154</b>, and may then realign the 3-D coordinate system with an updated spatial orientation. This recalibration procedure can occur at user-defined intervals and/or anytime a torque spike is encountered near the plane of tube sheet <b>80</b>. In an illustrative embodiment, the process can take less than ten seconds in practice, as machine movement can exceed five g's acceleration and five meters per second velocity. Once recalibration is complete, motion control computer <b>120</b> can once again find the precise center of each target every time.

0070In an illustrative embodiment, a method of cleaning tubes in a heat exchanger is also provided. The method can include, for example, the steps of digitally surveying the heat exchanger tube sheet in three dimensions to determine the location of the heat exchanger tubes, positioning a tube cleaning device adjacent to the heat exchanger tube sheet, and aligning the tube cleaning device with the heat exchanger tubes based upon the tube locations determined by the digital survey. In an illustrative embodiment, a possible additional feature may include storing the survey results obtained from the digital survey in a motion control computer. Another possible additional feature may include each of the steps of digitally surveying, positioning and aligning being controlled by a motion control computer.

0071In an illustrative embodiment, a system for cleaning tubes in a shell and tube heat exchanger is provided. The system can include a laser surface scanning device <b>100</b> for capturing three dimensional coordinates corresponding to the location of the tubes <b>88</b> in the heat exchanger <b>12</b> to be cleaned, a heat exchanger tube cleaning lance <b>90</b>, a heat exchanger tube cleaning lance positioning device <b>91</b>, and a motion control computer <b>120</b> for controlling the motion of the heat exchanger tube cleaning lance positioning device <b>91</b> with respect to the tubes <b>88</b> in the heat exchanger <b>12</b> based upon the three dimensional coordinates captured by the laser surface scanning device <b>100</b>.

0072In an illustrative embodiment, the system can recognize any potential collisions with personnel or equipment during the motion sequence and reverse direction before any injuries to personnel or damage to equipment occur. The servomotors can automatically and constantly relay torque information to the motion control computer <b>120</b>, and the motion control computer <b>120</b> can use this information in accordance with how it is programmed by the user.

0073In the event of a torque spike in the z-axis during cleaning due to a plug in a tube target, the system can be programmed to, for example, abandon the tube target and move to the next tube target, or alternatively, withdraw cleaning lance <b>90</b> slightly and enable the high-pressure jets to cut away the plug within the tube target for a user defined time period, then try again to pass through the plugged area. This process can be repeated until the target area is clean or until a user defined number of attempts have been tried unsuccessfully. The system can also allow for the jet pressure to be raised to a user defined maximum as required to successfully cut through difficult areas.

0074The system can integrate function, control, and vital signs for pump <b>60</b> and the related high pressure jets of cleaning lance <b>90</b> with motion control computer <b>120</b>. The system can allow for complete control of all pump functions, including engine start/stop, engage/disengage power take off (“PTO”), water supply valve on/off, raise/lower pressure, and high-pressure by-pass on/off. The system can also allow a user to monitor and adjust pump vitals such as water temperature, oil pressure, and voltage. This integration of pump <b>60</b> and the related high pressure jets of cleaning lance <b>90</b> with motion control computer <b>120</b> avoids the necessity for constant human interface at the location of the cleaning equipment and allows for a more efficient cleaning sequence.

0075In an illustrative embodiment, the system can be shut down or warnings can be initiated by motion control computer <b>120</b> if user defined thresholds are crossed. For example, the system can incorporate a safety light curtain as a safety barricade. The curtain can be multi-layered. If the curtain is encroached, the system may initiate an audible and visual alarm and/or shut down all high-pressure and motion, depending on what layer of intrusion has been encountered. In the case of a full breach with shutdown, a user with security credentials may then be required to declare the threat of injury passed and begin the restart procedure.

0076The system of the present invention can be operated continuously using shifts of operators to clean exchangers <b>12</b> quickly. Further, the system can incorporate networking and report generation capabilities. For example, assembly <b>10</b> can be linked to a local area network (“LAN”) and/or a secure server via wireless Internet to provide customers and/or operators with information regarding the job being performed. In an illustrative embodiment, motion control computer <b>120</b> can be communicatively coupled to a remote monitoring device via a communications network. This information can include, for example, real-time job progress, estimated time of completion, estimated cost at completion, current cost, current percent complete, and average time per tube. The system can also auto-generate a post-job report upon completion, which provides details about all events and activities that took place at each cleaning site. For example, the report can include a visual map of exchanger <b>12</b> relating to z-axis torque profiles to demonstrate increased or decreased fouling by percent of total fouling. This information can help customers and/or operators to better understand which regions of exchanger <b>12</b> are subject to frequent or enhanced fouling and make process adjustments to enhance run times and efficiencies.

0077In an illustrative embodiment, the assembly and system of the present invention do not utilize scanning device <b>100</b>. Instead, an operator can utilize motion control computer <b>120</b>, control console <b>20</b>, command station <b>44</b> and video cameras <b>30</b><i>a</i>, <b>30</b><i>b</i>, <b>30</b><i>c </i>&amp; <b>30</b><i>d </i>to identify specific groups of tubes <b>88</b> on tube sheet <b>80</b> for cleaning. The operator can select these groups of tubes <b>88</b> by, for example, identifying specific sections or regions of tube sheet <b>80</b> containing these groups of tubes <b>88</b>. The operator can then navigate the motion of one or more lances <b>90</b> to clean these groups of tubes <b>88</b>.

0078In an illustrative embodiment, five adjacent lances are utilized such as shown in <figref idref="DRAWINGS">FIG. 19</figref>. Alternatively, any combination of one or more lances <b>90</b> may be utilized as needed for efficient cleaning and would be in accordance with the present illustrative embodiments. Further, it is not required that lances <b>90</b> be aligned in parallel in every embodiment in which multiple lances <b>90</b> are utilized. Lances <b>90</b> may be staggered such that they form, for example, a triangular, rectangular or any other shaped pattern to correspond to the arrangement of multiple rows of tubes <b>88</b> on tube sheet <b>80</b>. Also, one or more of lances <b>90</b> may be protruded or retracted during a cleaning stroke such that, for example, only three of five, or two of five, lances <b>90</b> actually enter tubes <b>88</b> during cleaning. Such protrusion or retraction can be accomplished manually or using control console <b>20</b> and motion control computer <b>120</b>.

0079Lances <b>90</b> can be located within guide tubes <b>94</b>. Lances <b>90</b> can be positioned such that their tip ends <b>92</b> align with the open ends <b>86</b> of the tubes <b>88</b> of exchanger <b>12</b>. In an illustrative embodiment, the spacing between each lance <b>90</b> can be set manually using a bracelet <b>191</b> that slips over guide tubes <b>94</b> and/or lances <b>90</b>. Alternately, spacing between lances <b>90</b> can be controlled and adjusted by motion control computer <b>120</b> without the use of bracelet <b>191</b>. The size of bracelet <b>191</b> can be adjusted to correspond to the distance between the respective tubes <b>88</b> on tube sheet <b>80</b>. When spaced properly, the adjacent lances <b>90</b> are preferably able to enter and clean the adjacent tubes <b>88</b> of exchanger <b>12</b>.

0080During cleaning, assembly <b>10</b> can secure lances <b>90</b>. Assembly <b>10</b> can be mounted to exchanger <b>12</b> via frame <b>95</b> or other mounting means to restrict movement. Alternatively, assembly <b>10</b> can be positioned adjacent to exchanger <b>12</b> without being mounted thereon, such that cleaning lances <b>90</b> and tubes <b>88</b> of exchanger <b>12</b> are generally on the same horizontal plane and lances <b>90</b> can travel in and out of the respective tubes <b>88</b> with minimal resistance.

0081As illustrated in <figref idref="DRAWINGS">FIGS. 20A &amp; 20B</figref>, the movements of, and variables relating to, the components of assembly <b>10</b> can be controlled via command station <b>44</b>. In an illustrative embodiment, command station <b>44</b> may have one or more display modules and user input devices. For example, command station <b>44</b> can have one or more control consoles <b>20</b> with video monitor screens <b>46</b> for receiving live signals from cameras <b>30</b><i>a</i>, <b>30</b><i>b</i>, <b>30</b><i>c </i>&amp; <b>30</b><i>d</i>. A plurality of different camera angles may be viewed at any one time. For example, at least one of the camera feeds can display the heat exchanger head flange <b>84</b> and tube sheets <b>80</b> to allow the operator to view cleaning occurring at that location. Command station <b>44</b> can also have one or more control consoles <b>20</b> with touch screen monitors <b>300</b> that an operator may utilize to input and monitor information such as the location of assembly <b>10</b>, the positioning of lances <b>90</b> with respect to tubes <b>88</b>, and the cleaning of tubes <b>88</b> in exchanger <b>12</b>. Video monitor screens <b>46</b> and touch screen monitors <b>300</b> can all be viewable on a single control console <b>20</b>. Alternatively, each of video monitor screens <b>46</b> and touch screen monitors <b>300</b> can be viewable on two or more separate control consoles <b>20</b>, as desired. Command station <b>44</b> may also include one or more control consoles <b>20</b> with a manual operations station with buttons and instruments such as, for example, joystick controller <b>70</b>, as illustrated in <figref idref="DRAWINGS">FIG. 20B</figref>. Each of the various control mechanisms on command station <b>44</b> may be located on and integrated with, for example, a touch screen monitor, a video monitor screen or a manual operations station, and fall within the scope of the various illustrative embodiments.

0082Control console <b>20</b> and command station <b>44</b> can be integrated with motion control computer <b>120</b>. Motion control computer <b>120</b> can direct an operator through a series of steps for locating and cleaning tubes <b>88</b> of exchanger <b>12</b>. Each step can be performed via a different screen on touch screen monitor <b>300</b> of control console <b>20</b>. For example, an “exchanger information” screen <b>301</b> on touch screen monitor <b>300</b> (see <figref idref="DRAWINGS">FIG. 21</figref>) may be utilized, whereby an operator can input, store and retrieve basic preliminary information related to cleaning. This information can include such items as customer name <b>302</b>, exchanger ID# <b>303</b>, number of sections to define for cleaning <b>304</b>, horizontal tube spacing or tube centers <b>305</b>, and grid style <b>306</b>.

0083Customer name <b>302</b> can be used for cataloging and storing information regarding existing tube patterns for future cleanings. Exchanger ID# <b>303</b> can be the customer's ID for a particular heat exchanger <b>12</b> and can be used for cataloging and retrieval of information regarding the specific exchanger <b>12</b> for future cleanings. If the tube pattern of exchanger <b>12</b> has been previously defined, it can be retrieved using the exchanger ID# <b>303</b>, thus eliminating the need to describe and define the current tube pattern.

0084Number of sections <b>304</b> can be used to identify the number of sections that a tube sheet <b>80</b> will be divided into to accomplish the cleaning of heat exchanger <b>12</b>. Each section can be defined either manually, iteratively, or using a previously defined grid section, which may then be mirrored either vertically or horizontally (if necessary) to quickly build the next section. Iterative defining can be operator assisted in an illustrative embodiment. Tube spacing <b>305</b> can describe, for example, the distance or pitch between the center point of two horizontally adjacent tubes.

0085Grid style <b>306</b> can describe whether the exchanger tube pitch is square or triangular. In a square grid style, tubes <b>88</b> on tube sheet <b>80</b> may be positioned with the tube spacing equal on a horizontal and vertical plane. For example, if there are four tubes in a square pattern with a tube spacing of 1.25″ then the centers from tube to tube both horizontal and vertical will all equal 1.25″. In a triangular grid style, tubes <b>88</b> can be positioned on tube sheet <b>80</b> with an equilateral triangular pattern, such that the tube spacing is equal on a horizontal plane, but different on the vertical plane. In this case the system can use a mathematical formula to calculate the proper tube pitch and adjust the movements accordingly.

0086A “cleaning information” screen <b>310</b> on touch screen monitor <b>300</b> (see <figref idref="DRAWINGS">FIG. 22</figref>) may also be utilized, whereby an operator can input information regarding such cleaning parameters as tube length <b>311</b>, tube cleaning speed <b>312</b>, lance rotation speed <b>313</b>, and lance rotation direction <b>314</b>. Tube length <b>311</b> will be set by the operator. Among the possible styles of bundles to be cleaned are straight tube bundles and u-tube bundles. The distance on a straight tube bundle can be set to adequately deliver lance <b>90</b> through the entire length of tube <b>88</b>. On a u-tube bundle the tube length <b>311</b> can be set to clean to the tangent line of the bundle. This is because in a u-tube bundle, lance <b>90</b> can only clean to the tangent line without potentially damaging itself and/or tube <b>88</b>.

0087Tube cleaning speed <b>312</b> can indicate the speed in which lance <b>90</b> will travel through the bundle. In an illustrative embodiment, there can be two different speeds: a speed moving in, and a speed moving out. The system can be programmed to auto adjust itself to a slower speed if the system encounters obstructions or plugging inside of tube <b>88</b>. Thresholds can be set on the drive motor to back up and reduce tube cleaning speed before attempting to pass the obstruction. This can loop on pre-programmed intervals until the obstruction is overcome or the system hits a maximum attempt threshold and moves on to the next set of tubes <b>88</b>.

0088Lance rotation speed <b>313</b> can be measured in revolutions per minute (RPM). The lances <b>90</b> can rotate between 0-3000 RPMs in an illustrative embodiment. Rotation direction <b>314</b> can indicate the direction in which the lances <b>90</b> will rotate. Rotational direction <b>314</b> can be set at clockwise or counterclockwise, as desired.

0089A “section definition” screen <b>320</b> on touch screen monitor <b>300</b> (see <figref idref="DRAWINGS">FIG. 23</figref>) may also be utilized, whereby an operator can designate one or more sections on the face of tube sheet <b>80</b> of exchanger <b>12</b> and the tubes <b>88</b> in each specified section will be identified and cleaned. An operator can input, store and retrieve basic preliminary information related to each specific section on the face of tube sheet <b>80</b> that requires cleaning.

0090Initially, the operator can select a section for cleaning <b>321</b>. This relates back to the number of sections <b>304</b> that the operator defined on the “exchanger information” screen <b>301</b>. The operator may then define how the tubes <b>88</b> in that section will be identified. In the event that tube sheet <b>80</b> has multiple sections to be cleaned, the operator can define how cleaning will occur for each section.

0091Section definition can be through a manual process <b>322</b>, an iterative process <b>323</b>, or by using a previously defined section as a basis for defining the current section <b>324</b>.

0092Manual Process <b>322</b>

0093<figref idref="DRAWINGS">FIGS. 24</figref><i>a </i>&amp; <b>24</b><i>b </i>are illustrative examples of an edit screen <b>330</b> for the manual process <b>322</b>. Edit screen <b>330</b> can display a map that identifies the locations of tubes <b>88</b> on open end <b>86</b> of exchanger <b>12</b>. The map of edit screen <b>330</b> can display information for two dimensions (x &amp; y), or can be topographical and provide information for three dimensions (x, y &amp; z) in relation to open end <b>86</b> of exchanger <b>12</b>. In certain illustrative embodiments, an operator may utilize, for example, the touch screen functionality of edit screen <b>330</b> illustrated in <figref idref="DRAWINGS">FIGS. 24A &amp; 24B</figref>, the manual instruments illustrated on <figref idref="DRAWINGS">FIG. 20B</figref>, or a combination thereof, in performing manual process <b>322</b>.

0094For example, the operator can utilize edit screen <b>330</b> to select grid size from a number of existing options such as, for example, 15×15 or 25×25, or the operator can create a custom grid that corresponds to the pitch of tubes <b>88</b>, such as square or triangular. The custom grid can correspond to the spatial arrangement of tubes <b>88</b> on tube sheet <b>80</b>. If tube sheet <b>80</b> has more tubes <b>88</b> than the custom grid can create, that section can be divided into smaller sub-sections for cleaning. The tube centers and pitch can be determined by the information entered on the “exchanger information” screen <b>301</b>.

0095The tubes on edit screen <b>330</b> can correspond to the tubes <b>88</b> on the face of tube sheet <b>80</b>. The operator can indicate the specific operation that will occur for each tube <b>88</b>. The tubes on edit screen <b>330</b> can be color coded to indicate cleaning functions. In an illustrative embodiment, <figref idref="DRAWINGS">FIG. 24</figref><i>a </i>is the initial edit screen <b>330</b> with all tubes labeled gray (GR) to indicate that initially, none of the tubes have been designated for cleaning. <figref idref="DRAWINGS">FIG. 24</figref><i>b </i>is the edit screen after specific functions with corresponding color codes for the tubes have been entered. For example, navy blue tubes (NB) can indicate a home position, which is where the cleaning will begin and which can correspond to the location of lances <b>90</b> in the field. Yellow tubes (Y) can indicate tubes that will be cleaned. Green (G) can indicate tubes that have already been cleaned. Light blue (LB) can indicate tubes for which cleaning or designation is in process. Orange (O) can indicate a blocked tube. Gray tubes (GR) can indicate where tubes <b>88</b> have been excluded from cleaning. Maroon tubes (M) can indicate a mechanical plug. Brown tubes (B) can indicate a baffle exists immediately adjacent to this location. Dark green (DG) can indicate cleaned tubes, but with a baffle. Purple tubes (P) can indicate some other type of exclusion.

0096Once all relevant tubes have been marked on edit screen <b>330</b>, the operator can set the home position (NB) tubes, preferably by engaging the “Define Home” button <b>332</b> in an illustrative embodiment. In the field, assembly <b>10</b> can be positioned with respect to tube sheet <b>80</b> such that lances <b>90</b> are lined up with the open ends <b>86</b> of tubes <b>88</b> that correspond to the home position (NB) tubes on edit screen <b>330</b>. The operator can then engage the “Mark Home” button <b>333</b> in an illustrative embodiment. At this point, a start command can be initiated by engaging, for example, the “auto-start” button <b>351</b><i>a </i>as shown in the illustrative embodiment of <figref idref="DRAWINGS">FIG. 26</figref> when in the automated cleaning mode, and cleaning can begin. The system can then clean, or not clean, each tube <b>88</b> according to the specific instruction that was given for that tube <b>88</b> via edit screen <b>330</b>. Preferably, manual process <b>322</b> does not involve any repositioning of assembly <b>10</b> except to initially line up lances <b>90</b> with the home position (NB) tubes.

0097Iterative Process <b>323</b>

0098<figref idref="DRAWINGS">FIGS. 25A</figref>, <b>25</b>B, <b>25</b>C and <b>25</b>D are illustrative examples of an edit screen <b>340</b> for the iterative designation process <b>323</b>. In certain illustrative embodiments, an operator may utilize, for example, the touch screen functionality of edit screen <b>340</b> illustrated in <figref idref="DRAWINGS">FIGS. 25A</figref>, <b>25</b>B, <b>25</b>C and <b>25</b>D, the manual instruments illustrated on <figref idref="DRAWINGS">FIG. 20B</figref>, or a combination thereof, in performing iterative process <b>323</b>.

0099For example, the iterative process <b>323</b> can involve selecting a plurality of points or locations via edit screen <b>340</b> that define the outer perimeter of a region of tube sheet <b>80</b> to be cleaned. Lances <b>90</b> and/or guide tubes <b>94</b> can be moved to these various points or locations on tube sheet <b>80</b>, and the points or locations can be identified by motion control computer <b>120</b> as the outer boundary of a “cleaning region”. Motion control computer <b>120</b> may then instruct assembly <b>10</b> to clean the tubes <b>88</b> located at the identified point or locations.

0100In an illustrative embodiment, the operator can use joystick controller <b>70</b> and/or any other required instruments from command station <b>44</b>, such as the Up/Down/Left/Right buttons <b>76</b> as shown in <figref idref="DRAWINGS">FIG. 20B</figref>, to move lances <b>90</b> around the desired cleaning perimeter to effectively define the outer boundaries of the region to be cleaned.

0101<figref idref="DRAWINGS">FIG. 25A</figref> shows the initial edit screen <b>340</b> in an illustrative embodiment. Initially, edit screen <b>340</b> can display a grid of possible tube locations that correspond to tube sheet <b>80</b>. If desired, the operator can narrow down this quadrant to a grid size of, for example, 15×15, 25×25 or a custom grid less than 25×25. The operator can then define the region within the created grid that corresponds to the outer perimeter of tubes <b>88</b> to be cleaned.

0102In an illustrative embodiment of iterative process <b>323</b> where five lances <b>90</b> are utilized, the operator first selects five adjacent tubes <b>88</b> (either horizontal, vertical or diagonal) on edit screen <b>340</b> to be considered the home location. This will turn those tubes navy blue (NB) on edit screen <b>340</b>. Operator can then utilize joystick controller <b>70</b> to move lances <b>90</b> to the location on tube sheet <b>80</b> that corresponds to the home location. A “clean” button <b>75</b> (See <figref idref="DRAWINGS">FIG. 20B</figref>) can be engaged, and the tubes <b>88</b> corresponding to the home location can be cleaned.

0103The operator can next select a second location on the outer perimeter of the region to be cleaned and identify this location on edit screen <b>340</b>. The “clean” button <b>75</b> can be engaged, and the tubes <b>88</b> corresponding to this second location can be cleaned.

0104The operator can continue to designate the desired cleaning perimeter on tube sheet <b>80</b> by selecting additional locations on the perimeter to define a cleaning region and build a computer image of the tube sheet <b>80</b>. At each location, the “clean” button <b>75</b> can be engaged, and the tubes at that particular location can be cleaned.

0105Identifying the perimeter can involve selecting as few as four locations on tube sheet <b>80</b> to create a square region, or as many as twenty-six (or more) locations on a 25×25 grid, assuming one side has a jagged pattern. For example, <figref idref="DRAWINGS">FIG. 25B</figref> shows the edit screen <b>340</b> after a rectangular shaped cleaning region has been designated using four groups of five location points, <figref idref="DRAWINGS">FIG. 25C</figref> shows the edit screen <b>340</b> after a triangular shaped cleaning region has been designated using three single location points, and <figref idref="DRAWINGS">FIG. 25D</figref> shows the edit screen <b>340</b> after a non-uniformly shaped cleaning region has been designated using a plurality of groups having varying numbers of edit points.

0106Once the operator has defined the outer parameters for the desired region to be cleaned in the iterative process <b>323</b>, or the entire region to be cleaned in the manual process <b>322</b>, the operator can engage the “auto start” button <b>351</b><i>a </i>of <figref idref="DRAWINGS">FIG. 26</figref> in an illustrative embodiment. This indicates that designation of the outer perimeter of the region to be cleaned has been completed and cleaning of the tubes within this region can begin. At this time, lances <b>90</b> will return to the home location and begin the cleaning process.

0107In an illustrative alternate embodiment, iterative process <b>323</b> can involve identifying all the desired points on the perimeter of the region to be cleaned as an initial step. In a subsequent step, the “auto start” button <b>351</b><i>a </i>can be engaged to initiate cleaning of all the tubes <b>88</b> identified in connection with the initial step. At this time, lances <b>90</b> will return to the home location and begin the cleaning process.

0108Previously Defined Section <b>324</b>

0109When defining the section to be cleaned, the operator may mirror a previously defined section <b>324</b>, either left-to-right or up-to-down, using mirror buttons <b>800</b> (see <figref idref="DRAWINGS">FIGS. 24A</figref> &amp; B) in an illustrative embodiment. Mirror imaging can also be utilized in the manual <b>322</b> and iterative <b>323</b> processes in illustrative embodiments. Operator may also add or delete tubes <b>88</b> in the new mirror image. Alternatively, the operator may utilize the information from a previously defined section in one or more subsequent sections.

0110<figref idref="DRAWINGS">FIG. 26</figref> is an illustrative example of a cleaning-in-progress screen <b>350</b> for the manual process <b>322</b> and/or the iterative process <b>323</b>. In an illustrative embodiment, a “pause” button <b>352</b> can be utilized to pause the cleaning process, and the “auto start” button <b>351</b><i>a </i>can be utilized to re-start the cleaning process after being paused. In another illustrative embodiment, the “auto start” button <b>351</b><i>a </i>on cleaning-in-progress screen <b>350</b> can be utilized to begin the cleaning process after designation has occurred on edit screens <b>330</b> or <b>340</b>. Alternatively, a “start” button <b>331</b> can be provided on edit screen <b>330</b> or an “auto start” button <b>351</b> can be provided on edit screen <b>340</b> to begin the cleaning process directly from either of those screens, in an illustrative embodiment.

0111During the cleaning process, the crosshairs in <figref idref="DRAWINGS">FIG. 26</figref> can indicate the current position of lances <b>90</b>. The five tubes on the 3^rdrow, right hand side of <figref idref="DRAWINGS">FIG. 26</figref> designated by the crosshairs are in the process of being cleaned. The dark green tubes (DG) in <figref idref="DRAWINGS">FIG. 26</figref> have a baffle, and have already been cleaned. Mechanically plugged tubes can be identified by the color maroon (M), and tubes to be cleaned can been identified by the color yellow (Y).

0112In various illustrative embodiments, movement of lances <b>90</b> can be performed by an operator in the field or using cleaning-in-progress screen <b>350</b>, or otherwise via command console <b>20</b>. Further, in certain illustrative embodiments, automatic control, manipulation and navigation of lances <b>90</b> can comprise some level of robotic manipulation of lances <b>90</b>. Also, a plurality of add/exclude buttons <b>78</b> on control panel <b>20</b> (see <figref idref="DRAWINGS">FIG. 20B</figref>) can be utilized to add or remove one or more tubes <b>88</b> from the cleaning process as desired. Add/exclude buttons <b>78</b> can be utilized when defining the cleaning region or during actual cleaning. Further, add/exclude buttons <b>78</b> may be utilized during mirroring or during any other phase of the cleaning process described in the various illustrative embodiments.

0113In the event that assembly <b>10</b> and tubes <b>88</b> are not on a perfectly horizontal or vertical plane and/or do not line up properly, assembly <b>10</b> can tilt up, down, left or right to accurately line up with tubes <b>88</b>. Assembly <b>10</b> can include a motor and lance track tilt ram <b>701</b> to ensure that any tilt action stays level throughout the entire cleaning process, as needed. Further, in the event that open end <b>86</b> of heat exchanger <b>12</b> does not have a flush face (for example, a channel head), assembly <b>10</b> may be capable of extending forward and accessing the tube sheet even when a channel head is present. Lance track adjustment ram <b>700</b> can extend out to access tubes <b>88</b> as needed. An illustrative embodiment of lance track adjustment ram <b>700</b> and lance track tilt ram <b>701</b> are shown in <figref idref="DRAWINGS">FIG. 27</figref>.

0114A calibration routine can be used to determine the angular dimensions of tubes <b>88</b> within tube sheet <b>80</b>, which can be relevant in determining, for example, if assembly <b>10</b> or any of its components will need to be tilted or moved a distance from the horizontal plane in order to access tubes <b>88</b>. In an illustrative embodiment of the calibration routine, the operator can manually place the lances <b>90</b> within tubes <b>88</b>, at two different points, on the same row of tubes <b>88</b> of heat exchanger <b>12</b>. This can define the angle of tubes <b>88</b> within tubesheet <b>80</b> with respect to assembly <b>10</b>, thus determining the necessary tilt angle.

0115In the event that tube sheet <b>80</b> has an irregular cleaning pattern, assembly <b>10</b> can be modified to include any desired number of lances. For example, a single lance <b>90</b> may be utilized to do follow-up cleaning of any tubes <b>88</b> that could not be accessed by a five lance <b>90</b> system during initial cleaning.

0116<figref idref="DRAWINGS">FIGS. 28-33</figref> are flow diagrams for various illustrative embodiments of an automated heat exchanger tube and industrial pipe/tube cleaning method and system. <figref idref="DRAWINGS">FIGS. 28-33</figref> can be utilized in connection with a computerized program that is operational with motion control computer <b>120</b>, in an illustrative embodiment.

0117<figref idref="DRAWINGS">FIGS. 28A &amp; 28B</figref> are an illustrative embodiment of a pattern following routine <b>1000</b> having blocks <b>1001</b>-<b>1037</b>. This flowchart can utilize pattern data (as illustrated in <figref idref="DRAWINGS">FIG. 29</figref>) to navigate or move lances <b>90</b> sequentially through each tube <b>88</b> in tube sheet <b>80</b>. In an illustrative embodiment, this can be the main control program governing the navigation or movement of lances <b>90</b> and/or other components of assembly <b>10</b> in an automatic mode. This program can commence upon engaging the “auto start” button <b>351</b><i>a</i>, as shown in <figref idref="DRAWINGS">FIG. 26</figref>. After the “auto-start” button <b>351</b><i>a </i>has been engaged, lances <b>90</b> preferably move to the home position, which can be in either the upper right or upper left of the pattern on tube sheet <b>80</b> in an illustrative embodiment. Alternatively, home position can be any position that allows for ease of cleaning as determined by the operator. Starting at the home position, and following the mathematical definition of the grid, lances <b>90</b> can sequentially loop through each row of tubes <b>88</b> on tubesheet <b>80</b>, automatically cleaning the accessible tubes (in a multiple lance system). This sequential cleaning can continue until all of the accessible tubes <b>88</b> have been cleaned. In an illustrative embodiment in which multiple lances <b>90</b> are utilized and one or more tubes cannot be cleaned, the uncleaned tubes may be accessible using the program of <figref idref="DRAWINGS">FIG. 30</figref>.

0118<figref idref="DRAWINGS">FIG. 29</figref> is an illustrative embodiment of an add pattern data routine <b>1100</b> having blocks <b>1101</b>-<b>1114</b>. This flowchart can represent the decision tree used to receive the graphical information or other user input entered by the operator on the map of the tube sheet, either in the manual process <b>322</b> or the iterative process <b>323</b>. For the manual process <b>322</b>, it can be performed after the completion of the definition of the complete grid. For the iterative process <b>323</b>, it can be performed after the completion of the definition of the cleaning perimeter of the grid. In an illustrative embodiment, motion control computer <b>120</b> can scan the information on the display of edit screen <b>340</b> and process and convert this visual information to data usable by assembly <b>10</b>. Preferably, this is done by sequentially scanning each row. Additional pattern information can be added until a complete mathematical definition of the grid is accomplished.

0119<figref idref="DRAWINGS">FIG. 30</figref> is an illustrative embodiment of a single lance routine <b>1200</b> having blocks <b>1201</b>-<b>1238</b>. After all tubes <b>88</b> of tube sheet <b>80</b> have been cleaned using a setup with multiple lances <b>90</b>, there can be one or more tubes <b>88</b> on the tubesheet <b>80</b> which were not accessible and could not be cleaned. These tubes <b>88</b> can be cleaned one at a time after converting the multiple lance <b>90</b> configuration to a single lance <b>90</b> configuration. This decision tree of <figref idref="DRAWINGS">FIG. 30</figref> can coordinate the motion of a single lance <b>90</b> to each excluded tube <b>88</b>. Working through each section, the scattered uncleaned tubes <b>88</b> can be cleaned one-by-one using a single lance <b>90</b>. At each tube <b>88</b>, the operator can have the option of cleaning or skipping that tube <b>88</b>.

0120<figref idref="DRAWINGS">FIGS. 31 and 32</figref> are illustrative embodiments of iterative sub program routines <b>1300</b> &amp; <b>1400</b>, having blocks <b>1301</b>-<b>1318</b> and <b>1401</b>-<b>1412</b>, respectively. These two programs can work together to define reference points on the perimeter of the regions to be cleaned when using the button method. <figref idref="DRAWINGS">FIG. 32</figref> can be used to move a target position one step at a time in either the up, down, left, or right direction using up/down/left/right buttons <b>76</b> (see <figref idref="DRAWINGS">FIG. 20B</figref>). When the “clean” button <b>75</b> is pressed, <figref idref="DRAWINGS">FIG. 32</figref> can validate the target position and, if valid, add the target position to the perimeter of the region to be cleaned. The actual movement of lance <b>90</b>, as well as the actual cleaning of a tube <b>88</b>, can be performed using the program of <figref idref="DRAWINGS">FIG. 33</figref> in an illustrative embodiment.

0121<figref idref="DRAWINGS">FIG. 33</figref> is an illustrative embodiment of an iterative main program <b>1500</b> having blocks <b>1501</b>-<b>1529</b>. <figref idref="DRAWINGS">FIG. 33</figref> can represent the main decision tree for the iterative process <b>323</b> of defining the grid. In an illustrative embodiment, it can contain three parts: (1) a main control section for cleaning the tubes <b>88</b> which have been defined on the perimeter of the region to be cleaned; (2) a joystick method of defining the points on the perimeter, and (3) movement of lances <b>90</b> in response to the button method of defining points on the perimeter. <figref idref="DRAWINGS">FIG. 33</figref> does not include the actual definition of the points using the button method, only the movement of lances <b>90</b> in response to the definition. The button method of definition can be done in the illustrative embodiments of <figref idref="DRAWINGS">FIGS. 31 and 32</figref>. When a point has been marked on the perimeter of the region to be cleaned (using, for example, either the joystick controller <b>70</b> or the up/down/left/right buttons <b>76</b>), those tubes <b>88</b> may then be cleaned.

0122In an illustrative embodiment, assembly <b>10</b> may be located inside of a protective container <b>600</b> (not shown). Container <b>600</b> may have doors located on both ends. Container <b>600</b> can protect assembly <b>10</b> from outside elements such as rain, wind and can provide a more stable environment for shipping and relocating.

0123In an illustrative embodiment as shown in <figref idref="DRAWINGS">FIGS. 34-36</figref>, one or more components of assembly <b>10</b> may be capable of providing rotational motion for one or more lances <b>90</b>. For example, assembly <b>10</b> may include an apparatus for cleaning tubes on a tube sheet that includes at least one tube cleaning lance <b>90</b>, tube cleaning lance positioning device <b>91</b> for manipulating the motion of tube cleaning lance <b>90</b> with regard to one or more of the x, y and z planes, and a tube cleaning lance rotating device <b>99</b> for manipulating the rotational motion of tube cleaning lance <b>90</b>. Control console <b>20</b> can providing instructions to tube cleaning lance positioning device <b>91</b> and/or tube cleaning lance rotating device <b>99</b>. In an illustrative embodiment, assembly <b>10</b> can utilize one or more rotating lances <b>90</b> having non-rotating nozzles <b>96</b> to provide full coverage for the tube <b>88</b> being cleaned. In an illustrative embodiment, nozzle <b>96</b> does not rotate independently of rotating lance <b>90</b>. Rotating nozzles <b>96</b> can also be utilized, in another illustrative embodiment.

0124In an illustrative embodiment, assembly <b>10</b> may have a gearbox <b>199</b> or other carriage system that can house a plurality of lances <b>90</b> on equal centers from lance to lance allowing for rotation of all lances <b>90</b> from 0-3000 RPMs. Lances <b>90</b> may also be placed in a staggered pattern in gearbox <b>199</b> when, for example, tighter patterns are needed. In an illustrative embodiment, all lances <b>90</b> can be rotated using a series of pulleys <b>299</b> driven by a single belt <b>399</b> located within gearbox <b>199</b>. Alternatively, a series of gears can be utilized to rotate lances <b>90</b>, or a plurality of belts <b>399</b> or motors such as direct drive motors may be utilized, within the present illustrative embodiments.

0125In an illustrative embodiment, assembly <b>10</b> can be utilized to clean a variety of different types of exchangers <b>12</b>, as well as a variety of types of pipes used in industrial equipment. For example, in certain illustrative embodiments, assembly <b>10</b> can be lifted by a crane or other similar lifting device and disassembled and reassembled in the field in order to access exchangers in hard to reach locations. Assembly <b>12</b> can be used to clean tubes <b>88</b> in a vertically oriented exchanger <b>12</b> or otherwise in any vertical orientation, whereby, for example, assembly <b>10</b> can be positioned at or near the top end of exchanger <b>12</b> such that lances <b>90</b> are aligned with tubes <b>88</b>. Assembly <b>10</b> can also be used to clean, for example, fin fan exchangers or the shell side of a shell and tube exchanger. In an illustrative embodiment, assembly <b>10</b> and motion control computer <b>120</b> can be used to control the cleaning of an outside diameter of a tube bundle. A spray head system can be incorporated with assembly <b>10</b> that moves along the shell side of one or more bundles to clean the exterior of the bundles. Assembly <b>10</b> can also include a variable speed conveyer <b>650</b> (not shown). Items to be cleaned such as industrial piping, scaffolding, column trays or exchanger equipment can be placed on the conveyer <b>650</b>, and cleaning lance <b>90</b> or another cleaning instrument on assembly <b>10</b> can be used to clean these pieces of equipment as the equipment is moved by conveyer device <b>650</b>.

0126It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or illustrative embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example, complete automation of assembly <b>10</b> is also possible, if desired, through CNC technology. In other words, assembly <b>10</b> may operate automatically without the need for a human operator, or alternatively, the assembly <b>10</b> may be controlled by a human operator. Also, multiple digital scans of the exchanger tube sheet may be performed at any time during the cleaning process, if necessary. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.